01/04/2024 14:02:29

Hose - Supermanifold To 3 Way Valve And Radiator (Remove and Replace)

Correction code 18302202 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Raise and support vehicle.
Place vehicle in service mode with touchscreen.

Note
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box.
Access thermal system routines using the UI.

Note
Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock.
Select Start button at Start Thermal Fill Drain (Coolant Only) using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT window will appear.

Note
Select ‘X’ at top left of window to close once complete, Verify coolant status is green 'Ready for Fill/Drain' status, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again.
Remove the underhood storage unit. See .
Power off vehicle from center display.

Note
Via Controls > Safety & Security > Power Off.
Disconnect LV battery connector and First Responder Loop.

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection.
Release clip securing the supermanifold to battery pump supply hose from LV battery.

Note
1x clip.
Remove fasteners securing the LV battery and move aside.

Note
3x bolts, 10mm, 9 Nm, 2x datums, Take note of datums and carefully move assembly aside.
Release air quality sensor connection.

Note
1x connector.
Remove HEPA filter assembly cover.

Note
2x tabs, 2x datums, 2x slots, , Be cautious and do not damage the mounting clips, Maneuver cover forward and up in front of V-brace cross member.
Remove LV battery from vehicle.
Release upper connections on the front controller.

Note
2x locking connectors, Push in locking tabs and lift levers to release.
Release LH middle connection on the front controller.

Note
1x locking connector, Push in locking tab and lift lever to release.
Release RH middle connections on the front controller.

Note
2x locking connectors, Slide locking mechanism outwards to release.
Release lower connections on the front controller.

Note
2x locking connectors, Slide red locking tab outwards to release.
Remove bolt securing front controller ground cable.

Note
1x bolt, 10mm, 10 Nm.
Remove bolts securing front controller.

Note
3x bolts, 10mm, 10 Nm.
Remove front controller from vehicle and release ground cable from multi system beam.

Note
2x locating tabs, 1x ground cable.
Release frunk harness clip from body and move harness aside.

Note
1x fir tree clip, Secure harness to the side.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
Remove clips securing front aero shield.

Note
5x push clips.
Remove bolts securing front aero shield and remove from vehicle.

Note
9x bolts, 10mm, 6 Nm.
Place absorbent material below three way valve.

Note
Place to cover steering gear and front skid plate, Will prevent build up of fluid.
Place coolant catcher below front of vehicle.

Note
Position to catch all coolant loss.
Lower vehicle until tires are touching the ground.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Release thermal bar battery return hose from three way valve.

Note
1x hose clip, 2x plugs, Plug both ends.
Disconnect the sensor for the powertrain supply hose.

Note
1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector.
Disconnect powertrain supply hose from supermanifold.

Note
1x spring clip, Plug supermanifold and powertrain supply hose.
Disconnect the HV battery return hose from the Supermanifold.

Note
1x spring clip.
Disconnect 12mm thermal bar battery return hose from top LH side of radiator.

Note
1x spring clip, 1x clip, Release hose clip at AC compressor bracket to allow removal, Plug hose and radiator as needed.
Remove PT coolant pump from AC compressor bracket.

Note
Slide pump assembly away from compressor off lower bracket.
Guide thermal bar battery return hose between AC compressor bracket and PT coolant pump and between supermanifold and front drive unit.
Remove thermal bar battery return hose.

Note
Guide hose over multi-system beam.

Install

Position thermal bar battery return hose between supermanifold and front drive unit.

Note
Guide down hose over multi-system beam.
Guide thermal bar battery return hose between supermanifold and front drive unit and AC compressor bracket above PT coolant pump.
Connect 12mm thermal bar battery return hose to top LH side of radiator.

Note
1x spring clip, 1x clip, Secure hose clip at AC compressor bracket to after installation, Remove any plugs and secure hose, Perform push-pull-push test.
Secure thermal bar battery return hose onto three way valve.

Note
1x hose clip, 2x hose plugs, Remove any plugs and secure hose, Perform push-pull-push test.
Connect the HV battery return hose from the Supermanifold.

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated.
Secure powertrain supply hose to supermanifold.

Note
1x spring clip, Remove all plugs, Perform push-pull-push test to make sure hose is fully seated.
Connect the sensor for the powertrain supply hose.

Note
1x locking electrical connector, Engage locking tab.
Clean coolant residue from vehicle.
Return frunk harness to original position and secure clip.

Note
1x fir tree clip.
Position front controller for installation and position ground cable.

Note
2x locating tabs, 1x ground cable.
Install bolts securing front controller.

Note
3x bolts, 10mm, 10 Nm. Start with the side bolt.
Install bolt securing front controller ground cable.

Note
1x bolts, 10mm, 10 Nm.
Secure lower connections on the front controller.

Note
2x locking connectors, Engage red locking tab.
Secure RH middle connections on front controller.

Note
2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage.
Secure LH middle connection for front controller.

Note
1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage.
Secure upper connections for the front controller.

Note
2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
Remove absorbent material from below three way valve.

Note
Remove absorbent material and clean away all excess residue.
Clean coolant residue from vehicle.
Remove coolant catcher from under vehicle.
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.

Note
9x bolts, 10mm, 6 Nm.
Install clips securing front aero shield.

Note
5x push clips.
Lower vehicle until tires are touching the ground.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Remove coolant bottle cap.
Install frunk assembly.

Note
4x bolts, 10mm, 5 Nm.
Place empty coolant container into front storage area.
Fill container with at least 15L of coolant.
Place filled coolant container into front storage area.
Install vacuum refill cap onto coolant bottle assembly.
Setup coolant refill tool.

Note
Verify all valves on refill tool are in the closed position, See image for clarity.
Install vacuum refill hose into refill cap on coolant bottle.

Note
Perform push-pull-push test to verify hose is fully installed.
Place refill hose inside filled coolant container .

Note
Make sure hose end is fully submerged into coolant.
Position overflow hose into empty container.
Connect shop air supply to coolant refill tool.

Note
If not already done, Verify refill valve is set to off.
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve.

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed.
Slowly open the refill valve to allow coolant to be drawn into the system.

Note
Make sure hose end of refill hose is fully submerged during entire process.
Once the gauge reads zero, close the coolant refill valve.
Remove coolant refill hose from coolant container.
Remove coolant overflow hose from coolant container.
Remove vacuum refill hose from refill cap on coolant bottle.
Remove vacuum refill tool cap.
Remove coolant refill tool from vehicle.
Remove both coolant containers from inside underhood area.
Position LV battery into vehicle.

Note
Position LV battery to the left and allow space for HEPA cover to be installed.
Install HEPA filter assembly cover.

Note
2x tabs, 2x datums, 2x slots, Maneuver cover down and under V-brace cross member, Fully engage seal and locking tabs.
Secure air quality sensor connection.

Note
1x connector.
Install fasteners securing LV battery to multi-system beam.

Note
3x bolts, 10mm, 9 Nm, 2x datums, Shift into position and install fasteners.
Install clip securing the supermanifold to battery pump supply hose onto LV battery.

Note
1x clip.
Connect First Responder Loop and LV battery connector.

Note
2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated.
Access thermal system routines using the UI.

Note
Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock.
Select Start button at Start Coolant Air Purge using the UI and TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE - SUCCESS window will appear.

Note
Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required, Select ‘X’ at top left of window to close once complete.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is at the Max line, Top off fluid as required.
Install coolant bottle cap.
Exit Service Mode.

Note
Controls>Software select Exit Service Mode button.
Install frunk carpet.

Note
Verify carpet is properly seated under the seal.
Install frunk access panel.

Note
3x clips, 3x hooks, 1x connector.
Install front underhood apron.

Note
7x clips.
Install RH underhood apron.

Note
10x clips.
Install LH underhood apron.

Note
10x clips.
Install rear underhood apron.

Note
8x clips.
Close hood .
Remove vehicle from lift.

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".

Model S Service Manual

Hose - Supermanifold To 3 Way Valve And Radiator (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3